Development trends of 18650 lithium rechargeable battery forklift technology

　　1 Characteristics and market analysis of battery forklifts 18650 lithium rechargeable battery forklifts have the advantages of high energy conversion efficiency, low noise, no exhaust emissions, and easy control. They have higher environmental requirements in workshops, warehouses, food, pharmaceuticals, microelectronics, and instrumentation. It has been widely used in various occasions and has become the first choice tool for indoor material handling. With people's profound understanding of the dangers of environmental pollution, environmental protection has become the focus of common concern around the world. Therefore, battery forklifts with low noise and no exhaust emissions will become the mainstream of the market. In addition, the establishment of automated warehousing systems and large supermarkets has also stimulated the demand for indoor material handling machinery - battery forklifts. At present, the international production of battery forklifts accounts for more than 40% of the total forklift production. In developed countries such as Europe and the United States, the proportion of battery forklifts reaches 60%; in China, the proportion of battery forklifts is about 20%. Battery forklifts have now broken through the limitation that they could only be used for small-tonnage operations, and are gradually moving from indoor to outdoor, and the market demand is increasing year by year.

　　2 Development trends of battery forklift technology

　　2.1 The drive motor and electronic control are developing from DC to AC. Using AC electric control can improve productivity, accelerate quickly, increase vehicle driving speed and mast lifting speed, and the output torque is large when driving at high speed. Under the same working conditions, the energy consumption is small, which can extend the single-shift use time of the battery pack. In addition, the AC motor has no brushes and commutators and does not require regular maintenance, which reduces the operating costs of the entire AC control system. Well-known forklift companies such as Linde, Jungheinrich, Hyster, and Toyota have all launched AC battery forklift products.

　　2.2 Vehicle communication develops in the direction of networking. The CAN (Control Area Network) network is used to communicate between the control modules of battery forklifts. All electronic functional components become an integral virtual unit, which can exchange control information in real time and achieve synchronous control. Under the connection of two high-speed communication buses, it is very convenient for each independent functional component to access information from other functional components. CAN bus is a serial data communication protocol developed to exchange data between many control and test instruments in modern automobiles. The communication medium can be twisted pairs, coaxial cables or optical fibers, and the communication rate can reach 1Mbit/ s. Its biggest feature is that it abolishes the traditional station address encoding and replaces it with encoding the communication data block. The CAN protocol uses CRC checking and can provide corresponding error handling functions to ensure the reliability of data communication. Applying CAN to the battery forklift control system improves the reliability and communication speed of data communication, reduces the cost of the control system, and greatly improves the control level of the battery forklift. Both Linde Company and Anhui Forklift Group Company have successfully applied CAN bus technology to battery forklifts.

　　2.3 The steering system is moving toward electronics. The traditional battery forklift steering system uses mechanical steering or hydraulic power steering. The disadvantage of mechanical steering is that the operating force is large and the operator is prone to fatigue; while the disadvantage of hydraulic power steering is that it wastes energy. The use of electronic steering not only reduces the operating force, but also saves about 25% of energy than hydraulic power steering. At present, there are two main types of electronic power steering systems: one is a position feedback electronic power steering system, which is used in the products of Jungheinrich Company and Anhui Forklift Group Company; the other is a torque feedback electronic power steering system. The products of Linde Company and TCM Company adopt this electronic power steering system.

　　2.4 The control system develops in the direction of integration. As operators have higher and higher requirements for control comfort, integrated control has become a development trend. The so-called integrated control is to use one joystick to complete all the control actions of the battery forklift: forklift forward/reverse, mast forward/retreat, mast rise/fall, fork tilt forward/rearward, fork left/right move Side shift. In this way, the labor intensity of operators can be reduced, thereby improving labor efficiency. At present, the products of Jungheinrich Company and Anhui Forklift Group Company have adopted this comfortable and convenient integrated control system.

　　2.5 The braking system develops in the direction of electronics. In order to reduce braking impact and enhance applicability, the braking torque of the transmission system is required to be adjustable, thus promoting the development of adjustable torque electromagnetic brakes. The adjustable torque brake consists of a spring-loaded brake and an electronic control device - a torque controller. This electromechanical integrated braking system not only realizes the adjustable braking torque function, but also can control the brake through the torque controller. The wear and tear can be monitored to improve the reliability of the system and reduce operation and maintenance costs. In addition, this adjustable torque brake can also be equipped with a CAN bus interface to realize remote diagnosis and control of the brake and networked operation of brake control.

　　2.6 Application of hydraulic pump motor controller The hydraulic pump motor controller can control the motor to achieve stepless speed regulation of the mast lifting/forwarding/retreating, etc. It can also set the motor speed to control the fork tilt/side movement speed. Using a hydraulic pump motor controller can save 25% of energy, extend the battery pack's single-shift use time, and reduce the heat generation of the hydraulic system. Battery forklifts such as Linde, Jungheinrich, TCM, Anhui Forklift Group Company, etc. all use hydraulic pump motor controllers.

　　2.7 The mast lowers using load potential energy recovery technology. The mast lowers uses load potential energy recovery technology to achieve stepless speed regulation of the mast lowering, and can also save 5% of energy. The principle of load potential energy recovery is: when the mast is lowered, the hydraulic pump becomes a hydraulic motor and the electric motor becomes a generator, which converts the potential energy of the load into electrical energy to charge the battery to achieve the purpose of saving energy. 3Conclusion

　　User needs have promoted the development of 18650 lithium rechargeable battery forklifts. Saving energy, improving reliability, reducing use and maintenance costs, and improving operating comfort have become the development directions of battery forklifts.

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